RINNAI DEMAND DUO WARM WATER VALVE Owners Guide and Installation Instructions

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RINNAI DEMAND DUOWARM WATER VALVEModels: DDWW32, DDWW50 & DDWW80

Owners Guide and Installation Instructions

allation, commissioning, operation, maintenance and service t be performed by persons competent and permitted by law o so in accordance with the manufacturers instructions and

relevant requirements of:

S/NZS 3500.4S 3000

Distributed and serviced in Australia under a Quality System certified as complying with ISO 9001 by SAI Global

S 4032.3cal codes and regulatory authorities

i

ii

SAFETY ...................................................................................................................... 1

APPLICATION .................................................................................................................................. 1

FOR YOUR SAFETY ........................................................................................................................ 1

REGULATORY MATTERS ............................................................................................................... 1

SPECIFICATIONS ...................................................................................................... 2

MODEL: DDWW32 ........................................................................................................................... 3

MODEL: DDWW50 ........................................................................................................................... 5

MODEL: DDWW80 ........................................................................................................................... 7

PRINCIPLE OF OPERATION..................................................................................... 9

PRINCIPLE OF OPERATION (Figure 1) .......................................................................................... 9

WATER QUALITY .................................................................................................... 10

WARRANTY ............................................................................................................. 10

FAULT FINDING DURING NORMAL OPERATION ................................................ 10

SYSTEM DESIGN ........................................................................................................................... 11

SYSTEM DESIGN..................................................................................................... 11

INSTALLATION........................................................................................................ 14

GENERAL INFORMATION ............................................................................................................. 14

LOCATION ...............................................................................................................14

INSTALLATION ........................................................................................................14

COMMISSIONING .................................................................................................... 15


FILLING THE SYSTEM ............................................................................................15

COMMISSIONING CHECKS .......................................................................................................... 16

HAND-OVER TO CUSTOMER .................................................................................17

CHECKING AND MAINTENANCE........................................................................... 18


PERFORMANCE CHECKING PROCEDURES .............................................................................. 18

CHECKING AND MAINTENANCE........................................................................... 19

MAINTENANCE PROCEDURES .................................................................................................... 22

COMMISSIONING LOG ........................................................................................... 23

MAINTENANCE LOG............................................................................................... 24

CONTACTS .............................................................................................................. 25

TABLE OF CONTENTS

Rinnai Australia 1 Demand Duo Warm Water Valve Owners Guide & Installation Manual

SAFETY

APPLICATION

The outlet of the Demand Duo warm water valve delivers warm water by blending hot water from aseparate water heating system with cold water by means of an electronically controlled thermostaticmixing valve across a wide range of flow rates with minimal pressure drop.

FOR YOUR SAFETY

The delivery temperature of the Demand Duo warm water valve must be set in accordance with localauthority requirements for the intended application.

The risks associated with legionella bacteria must be controlled in accordance with local authorityrequirements. Ultraviolet Disinfection (UV) units are available from Rinnai as an optional extra to formpart of a maintenance regime to safeguard against legionella bacteria.

Warm water system design must be carried out by persons competent to do so.

Installation, commissioning, operation, maintenance and servicing must be performed by personscompetent and permitted by law to do so in accordance with the manufacturers instructions and therelevant requirements of:

For the Demand Duo warm water valve to operate safely, the operating parameters must be inaccordance with those detailed in the '“SPECIFICATIONS” on page 2' section of this document.

Periodic performance checking and maintenance are recommended. Guidelines for performancechecking and maintenance are given in the section “CHECKING AND MAINTENANCE” on page 18.

The person or organisation responsible for the warm water valve and associated plumbinginfrastructure in a premises must exercise due diligence to ensure that the delivery temperature doesnot exceed the allowable temperature for a particular application and that the risks associated withlegionella bacteria are effectively managed.

REGULATORY MATTERS

The Rinnai Demand Duo warm water valve is certified as meeting the requirements of AS 4032.1when set at temperatures not exceeding 45°C. AS 4032.1 applies to thermostatic mixing valves.

The Rinnai Demand Duo warm water valve is certified as meeting the requirements of AS 4032.2when set at temperatures not exceeding 50°C. AS 4032.2 applies to tempering valves.

Details of certification are shown on the dataplate of the appliance.

It is a requirement in New South Wales that warm water system installations are registered with thelocal council or other relevant regulatory authority. There may be similar requirements in other Statesor jurisdictions.

• AS/NZS 3500.4 • AS3000 • AS4032.3 • Local codes and regulatory authorities

• DO NOT operate this system before reading these instructions

• DO NOT place articles on or against this appliance

• DO NOT store chemicals or flammable materials near this appliance WARNING

SPECIFICATIONS

TABLE 1 - SPECIFICATIONS

Models DDWW80 DDWW50 DDWW32

Mixed outlet flow rate at corresponding pressure loss through system

360 l/min at 60 kPa 165 l/min at 60 kPa 61 l/min at 60 kPa



Maximum static and dynamic working pressures

1000 kPaIMPORTANT: The pressure limitations of the Water Heater must also be considered. When installed with Rinnai Demand Duo observe the pressure limitations specified.

Maximum dynamic differential pressure between hot and cold supplies to mixing port.

50 kPa

Hot inlet temperature range 60° to 70° C

Cold inlet temperature To be less than mixed outlet temperature setting

Minimum 'mixed return' flow rate

54 l/min 24 l/min 14 l/min

Electrical power supply 240 Volts, 50 Hz

Average power consumption 24 W 20 W 15 W

Dimensions: (mm)

WidthHeight:Depth:

12001640666

Weight: 135 kg 90 kg 70 kg

Cold inlet connection * 3” RP 2” RP 1 1/4” RP

Hot inlet connection * 2” RP 1 1/4” RP 3/4” RP

Mixed outlet connection * 3” R 2” R 1 1/4” R

Mixed return connection * 2” R 1 1/4” R 3/4” R

Cold to Water Heaterconnection *

2” RP 1 1/4”RP 34” RP

* All connections are pipe threads of Whitworth form.


SPECIFICATIONS

MODEL: DDWW32

462

462546

8221182

1486

1200

147

291

291

516

1640

150

147

291

Mix

OUT

LET

Mix

RETU

RN

CO

LD

INLE

T

HOT I

NLE

TC

old

to

Wat

erhe

ater


SPECIFICATIONS

MODEL: DDWW32

1 2 3 5 9

13

104

14121916

18

1517

11

208

6 719

A

ITEM

NO

.D

ESC

RIP

TIO

N1

ELBO

W B

R 3

/4" F

2BU

SH T

UBE

BR

S 20

C x

20

MI

3BA

LL V

ALVE

LEV

ER4

NIP

PLE

HEX

BR

S 3/

4"5

UN

ION

BAR

REL

M&F

LIG

HT

6C

HEC

K VA

LVE

SWIN

G B

RZ

7TE

E BR

3/4

"8

BUSH

TU

BE B

RS

32 C

x 3

2MI

9TE

E BR

ASS

32 m

m10

BUSH

RED

11/

4 M

x 3

/4 F

111/

2" S

OC

KET

12N

IPPL

E 1/

2"13

VALV

E N

ON

RET

SPR

ING

14ST

RAI

NER

BR

20 m

m15

DN

32 T

YPE

B16

DN

20 T

YPE

B17

ELBO

W C

U 3

/4"

18C

U E

LBO

W 3

2 m

m19

RED

UC

ER C

ON

CU

19A

RED

UC

ER C

ON

CU

20TE

E C

U-3

/4" x

3/"

x 3/

4"21

VALV

E BA

LL B

R 1

5 m

m M

-F

21


SPECIFICATIONS

MODEL: DDWW50

1642

1200

29714

7

395

11871485

576

238

150

516

1640

147 29

7

Mix

OUT

LET

Mix

RETU

RN

CO

LD

INLE

T

HOT

INLE

T

CO

LD to

W

ATE

R HE

ATE

R


SPECIFICATIONS

MODEL: DDWW50

1 2 5 7 9 10368

1115

4 13

141618

17

19

20

12

ITEM

NO

.D

ESC

RIP

TIO

N1

32 m

m B

RS

M x

F E

LBO

W2

32 m

m B

RS

BRAZ

ING

BU

SH3

32 m

m B

ALL

VALV

E4

BRS

HEX

NIP

PLE

532

mm

M x

F B

ARR

EL U

NIO

N6

32 m

m S

WIN

G C

HEC

K VA

LVE

7BR

S TE

E8

50 m

m B

USH

TU

BE9

50 m

m B

RS

TEE

1050

~ 3

2 M

M B

RS

RED

111/

2" S

OC

KET

12N

IPPL

E 1/

2"13

32 M

M S

PRIN

G C

HEC

K VA

LVE

14ST

RAI

NER

15D

DN

50 T

YPE

B16

DN

32

TYPE

B17

CU

ELB

OW

2"

18C

U E

LBO

W 3

2 m

m19

CU

RED

50

x 32

mm

20C

U T

EE 3

2 m

m21

VALV

E BA

LL B

R 1

5 m

m M

-F

21


SPECIFICATIONS

MODEL: DDWW80

1200

385

499

385821

12151533

100

323

666

100

150

1640

323

HOT

FRO

M D

DC

OLD

IN T

O D

D

CO

LD IN

LET

Mix

RETU

RNM

ix O

UTLE

T


SPECIFICATIONS

MODEL: DDWW80

1 2 3 4 5768 9 10 13

1115

17

18 16 1419

20

ITEM

NO

.D

ESC

RIP

TIO

N1

ELBO

W B

RS

50 M

M M

&F2

BUSH

TU

BE B

RS

50 C

X 5

0 M

I3

VALV

E BA

LL W

ATER

BR

50

mm

- F-

F4

NIP

PLE

HEX

BR

S 50

MM

5U

NIO

N B

ARR

EL M

&F L

IGH

T 50

mm

6VA

LVE

NO

N R

ET 5

0 m

m7

TEE

BRS

50 m

m8

TUBE

BU

SH 8

0 C

x 8

0 M

I9

TEE

BRS

80 m

m10

BUSH

RED

BR

80

mm

- 50

mm

111/

2"SO

CKE

T12

NIP

PLE

1/2"

13VA

LVE

NO

N R

ET S

PRIN

G 5

0 m

m14

STR

AIN

ER B

R 5

0 m

m15

DN

80 T

YPE

B16

DN

50 T

YPE

B17

ELBO

W F

XF P

RES

S C

U80

mm

18EL

BOW

CU

2" T

O A

S 36

8819

RED

UC

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ON

CEN

TRIC

CU

20TE

E H

IGH

PR

ESS

CU

50

mm

21VA

LVE

BALL

BR

15

mm

M-F

12 21


PRINCIPLE OF OPERATION

PRINCIPLE OF OPERATION (Figure 1)

The Demand Duo warm water valve connections comprise the 'cold supply' , the 'hot supply', 'mixed delivery' and 'mixed return' . For maximum safety, the 'cold supply' to the

warm water valve and the water heating system are connected to the same source via the 'coldto water heater' connection . Warm water is delivered to the warm water outlets via apumped flow and return system. The design of the 'flow and return' loop and the flow and returnpump system must result in the minimum 'mixed return' flow rate specified being achieved(See “SPECIFICATIONS” on page 2.). The Demand Duo warm water valve is unsuitable forinstallation as part of plumbing systems that do not incorporate a 'flow and return' loop and pumpsystem.

An electronic temperature sensor measures the warm outlet temperature and sends an electronicsignal to the system controller . The system controller sends an operating voltage to a magneticactuator directly coupled to a three way water mixing port . The three way water mixing portmixes 'hot inlet' and 'cold inlet' water to achieve 'mixed outlet' water at a set temperature.The positioning of the three way mixing port controls the ratio of 'hot inlet' and 'cold inlet' water and therefore the temperature of 'mixed outlet' water. This positioning in turn depends uponthe voltage sent by the system controller to the magnetic actuator .

Warm water returning to the system via the system 'mixed return' connection can flow to the 'coldinlet' and/or to the water heating system via the 'cold to water heater' connection and thento the 'hot supply' and 'hot inlet' in any proportion determined by the system controller andpositioning of three way mixing port . In this way, the system controls the mixed water temperatureunder all specified conditions.

An ultraviolet disinfection system is available as an optional extra.

Figure 1 - Principle of Operation

i 1113 10 9 11

ii12 16

iii15 9

12 3

4 56 7 8

5 6 78

2 4

97 ii 12

13 6 25

14

11

6

4 5

2 15

9

12

13

10

8

7

14

3

1

16iii

ii

i


WATER QUALITY

Warranty applies to Demand Duo warm water valves supplied from a reticulated water supply from agovernment water utility. It does not apply if supplied from any alternative water supplies if the waterchemistry and impurity levels of alternative water supplies exceed the limits specified in the separatewarranty booklet. Examples of alternative water supplies include private bore water, water fromprivate dams and water supplied from a reticulated water supply but where the water chemistry isdeliberately altered before supplying the warm water valve.

Warranty terms and conditions are detailed in the separate warranty booklet.

The Table below applies when the warm water system is in normal operation and a fault is apparent.

TABLE 2 - FAULT FINDING DURING NORMAL OPERATION

FAULT POSSIBLE CAUSES REMEDY

Delivery temperature not hot enough

Warm water valve system power supply switched off Check and turn on the power supply

No electrical or gas supplies to the hot water systemCheck and turn on the gas and electricity supplies

Power supply to circulating pumps switched offCheck and turn on circulating pump power supplies

Other

Arrange for a service person to check and rectify. This work must be performed by persons permitted by law to do so.

No water flowing from warm water outlets

The mains cold supply to the warm water valve and/or water heating system is isolated.

Note: For maximum safety it is recommended that the cold water supply to the warm water valve and the water heating system are connected to the same source.

Check position of 'mains cold supply' to warm water system (See Figures 2 & 3).Important: Do not alter the position of any other valves in the system

Other


Delivery temperature too hot

To prevent scald injury, immediately isolate mains supply to the warm water valve and/or water heating system.


Other


WARRANTY

FAULT FINDING DURING NORMAL OPERATION


SYSTEM DESIGN

SYSTEM DESIGN

Figures 2 and 3 show a typical installation of a Demand Duo warm water valve with a Demand Duomains pressure gas storage water heating system and associated hot and warm water 'flow andreturn' loops and components. The system consists of the Demand Duo warm water valve , waterheating system , flow and return system piping for warm water , flow and return piping for hotwater (if required) , Ultraviolet disinfection system (optional) interconnection piping and allassociated fittings such as valves, unions and pumps. System design must be carried out by persons competent to do so and must ultimately be such thatthe water temperature at all points is acceptable for the intended application and that legionellabacteria growth can be effectively managed. These considerations are critical. Important design considerations include the following: 1. For maximum safety it is recommended that the cold water supply to the warm water valve

and the water heating system are connected to the same source. To facilitate this, the warmwater valve has a 'cold to water heater' connection . The 'mains cold' supply pipe forboth the warm water valve and water heating system is connected to the 'cold inlet'connection of the warm water valve. The cold water supply to the heated water system is thenprovided via the 'cold to water heater' connection of the warm water valve.

2. To facilitate continuing the warm water supply whilst servicing the Ultraviolet Disinfection unit, awarm water by-pass should be installed as shown. It is recommended to remove the handlefrom the by-pass isolating valve and keep it in a safe place during normal operation to preventunauthorised opening.

3. The number and location of isolating valves in Figures 2 and 3 have been determined soservicing and system checking activities can be carried out efficiently and with minimal disruption.

4. The mains cold supply pipe contains a main isolating valve and pressure limiting valve (if required). The pressure limiting valve must not be located in any other position as this willresult in different hot and cold water supply pressures to the three way mixing port . A'non return' valve is not required to be fitted in the mains cold supply pipe as the warm watervalve already contains all 'non return' valves required for the warm water system to preventbackflow into the cold supply.

5. It is a mandatory requirement that an expansion control valve is fitted. The expansion controlvalve must be located in the pipework between the 'cold supply connection to water heater' from the warm water valve and 'hot inlet’ connection of the water heater . It must not belocated in any other position.

6. The warm water valve and water heater must both be sized for the intended application.

7. Flow and return pipe sizing and configuration and flow and return pump specification must besuch that the following requirements are met:

i. The 'mixed return' flow rate to the warm water valve is equal to or greater than the minimum flow rate specified for the system selected (see “SPECIFICATIONS” on page 2), and

ii.The desired delivery temperature is obtained at any warm water outlet .

8. The Ultraviolet Disinfection system (optional) must be sized for the flow rate through the flowand return system.

9. The maximum dynamic differential pressure between the 'cold inlet' and 'hot inlet' connections to the three way mixing port must not exceed the limit of 50 kPa under all flowconditions (see “SPECIFICATIONS” on page 2). It is desirable that the system design achievesthis without the use of devices such as balancing valves. The length, size and path of thepipework between the warm water valve and the water heating system will greatly influencethe differential pressure achieved.

10. Isolating valves supplied by the installer must be full flow ball or gate valves.

32 4

1 5

A 3

2

3 B A

3 2

C

B

D

A E 6

6

H G O

A

F

F B

3 N

3 2

L

K

9

5

G J

O

3 2


SYSTEM DESIGN

Figure 2 - Demand Duo Warm Water Valve - Typical Installation

Equ

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ent F

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ork

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7

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ater

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pans

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trol

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(Man

dato

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SYSTEM DESIGN

Figure 3 - Demand Duo Water Valve Component Identification

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B

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EF

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atio

n Va

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atio

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iner

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alve

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ain

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atio

n Va

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ater

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ater

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INSTALLATION


GENERAL INFORMATION

Installation, commissioning, operation, maintenance and service must be performed by personscompetent and permitted by law to do so in accordance with the manufacturers instructions and therelevant requirements of:

The Demand Duo must be installed in accordance with the 'Rinnai Demand Duo Installation Manual'.

It is important that the Installer understands the operational principles of the system beforecommencing installation.

The Demand Duo warm water valve is unsuitable for use in pool heating applications.

For external installations of the Demand Duo warm water valve adequate provisions against ingressof water, wind and sunlight must be made.

Access by unauthorised persons must be prevented.

The Ultraviolet Disinfection system (if fitted) must be installed in accordance with manufacturerinstructions.

LOCATION

The Demand Duo warm water valve should be located in close proximity to the water heater systemto minimise dynamic pressure differences between the hot and cold water inlets to the three waymixing port.

Locate all system components to allow the cold water supply to the warm water valve and the waterheating system to come from the same source. The warm water valve has a 'cold to water heater'connection to facilitate this.

It is recommended that the warm water valve, water heating system and Ultraviolet Disinfectionsystem (if fitted) are installed at ground or floor level. They must be accessible without the use of aladder or scaffold. All components must be accessible for service and removal. With this in mind it isrecommended that a clearance of at least 900 mm is maintained around the perimeter of thesesystems. Installation in roof spaces is not recommended and may contravene local authorityregulations.

The warm water valve control box requires electrical power from a switched AC 240V, 50 Hz, earthedmains power outlet rated at 10 A or higher. The system will not operate without electrical power. Thepower supply cord supplied is 2 metres long.

The Ultraviolet Disinfection system also requires electrical power. Locate the UV system componentsin accordance with manufacturers instructions.

Plan the installation layout of the warm water valve in relation to the water heating system andplumbing infrastructure. Use suitable anchors to secure the warm water valve assembly base to thefloor.

Locate all system components to prevent access by unauthorised persons.

INSTALLATION

Connection sizes are shown in the “SPECIFICATIONS” on page 2. Connections can be made directlyto the warm water valve without the need for disconnection unions as all warm water valve connectionpoints contain wrenching flats. Connections to all other system components must incorporatedisconnection unions.

Flush and clean all water supply pipes before connection.

Install the Demand Duo warm water valve, water heater, flow and return system piping for warm water,flow and return piping for hot water (if required), Ultraviolet disinfection system (if fitted)interconnection piping and associated valves, unions and pump system components.


• Ensure the mains cold water inlet remains closed until commissioningcommences.

• DO NOT fill any components with water at this stage. • DO NOT connect the Demand Duo warm water valve, Ultraviolet Disinfection

system (if fitted) and any of the circulating pumps to the electrical power suppliesat this stage.

• DO NOT connect the electric and/or gas supply to the water heating system at thisstage.

IMPORTANT

COMMISSIONING

GENERAL INFORMATION

Commissioning must be performed by persons competent and permitted by law to do so inaccordance with the manufacturers instructions and the relevant requirements of:

During commissioning the system is filled with water and switched on so that water heatingcommences. Commissioning checks are then carried out to set and confirm system performanceparameters under various operating conditions.

FILLING THE SYSTEM

To fill the system, follow the steps below (Refer to Figure 2 page 12 and Figure 3 page 13):

Step 1. Open every warm water tap in the building (do not forget the showers).

Step 2. Close the 'cold inlet' to the three way mixing port .

Step 3. Progressively open all other remaining system isolation valves including those on the waterheating system and flow and return pumps.

Step 4. Air will begin to be forced out of the warm water taps. As water flows freely from each tap,close it.

Step 5. Open the 'cold inlet' to the three way mixing port .

Step 6. Open the nearest warm water tap . Any remaining air will be forced out. Once waterflows freely from the tap, close it.

Step 7. Check the pipe work for leaks.

Step 8. Open the PTR valve on each hot water system storage cylinder, in turn, to check that eachis filled with water.

Step 9. Ensure that the inlet and outlet isolating valves to the Ultraviolet Disinfection unit areopened and that the 'bypass' valve is closed.

Step 10. Prime all circulating pumps , and in accordance with the manufacturersinstructions. This will usually involve removal of the brass or chrome 'bleeding' screw andallowing a small quantity of water to drip out in the vicinity of the end of the pump shaft.

Step 11. Activate the power supplies to the circulating pumps and Ultraviolet Disinfection system (if fitted) in accordance with manufacturers instructions.

Step 12. Activate the power supply to the Demand Duo warm water valve .

Start the water heating system in accordance with manufacturers instructions to commence waterheating.


• Ensure building occupants DO NOT have access to any heated water outlets during thecommissioning process due to a risk of scald injury.

IMPORTANT

9 G

G

9

D

L M R

5

3


COMMISSIONING

COMMISSIONING CHECKS

Pre-commissioning Checklist

Before carrying out any commissioning checks, confirm the following:

1. Has it been ensured that building occupants do not have access to any heated water outletsduring the commissioning process?

2. Is the Demand Duo warm water valve installed in accordance with these installation Instructions?

3. Is the water heating system installed and commissioned in accordance with the relevantinstructions?

4. Is the Ultraviolet Disinfection system installed in accordance with the relevant instructions?

5. Has the system been filled with water and has all air been expelled?

6. Has the installation been checked for leaks and have all leaks been rectified?

7. Have the water supply lines been flushed and cleaned?

8. Have the line strainers been cleared?

9. Has the water heating system been switched on and has the hot water temperature reached atleast 60°C?

10. Are system valves and taps opened or closed as required (see “FILLING THE SYSTEM” onpage 15).

11. Is the power supply to the Demand Duo warm water valve switched on?

12. Is the power supply to the Ultraviolet Disinfection system switched on?

13. Are all circulating pumps primed and switched on?

Setting and checking Warm Water Delivery Temperature

The warm water delivery temperature obtainable by the end users must be compatible with theintended application and comply with AS 3500.4 and applicable local regulations and requirements.During commissioning the warm water delivery temperature must be set, checked and adjusted (ifrequired) for every installation as applications and site conditions vary.

The Demand Duo warm water valve is factory pre-set to deliver warm water at a temperature of 43°C. It can be adjusted on site to deliver water at a temperature in the range of 35°C to 55°C. Deliverytemperatures must always be checked using a calibrated thermometer with suitable accuracy andrecorded. The “COMMISSIONING LOG” on page 23 of these instructions can be used for recordingpurposes.

During commissioning set, check and adjust warm water delivery temperature in accordance with theprocedure '“Checking Water Temperature - Full Test” on page 18 as described in the section“PERFORMANCE CHECKING PROCEDURES” on page 18. The procedure “Checking WaterTemperature - Partial Test” on page 19 is not suitable for commissioning purposes.

Checking the warm water delivery temperature obtainable by the end users also forms part of theperformance checking and maintenance procedures outlined in the section “CHECKING ANDMAINTENANCE” on page 18 and should be performed at least once every 12 months.

Differential Pressure Check

The maximum pressure difference between the hot and cold water inlets to the three way mixing portunder flow conditions (dynamic differential pressure) must not exceed 50 kPa for the system toperform as specified (see “SPECIFICATIONS” on page 2). This is checked by connecting a suitabledifferential pressure gauge. Perform the ‘differential pressure check’ procedure as described in thesection “PERFORMANCE CHECKING PROCEDURES” on page 18.


COMMISSIONING

Cold and Hot Water Supply Failure Tests

The cold water supply failure test simulates the failure of cold water supply to the warm waterinstallation whilst a hot water supply still exists. Under these conditions, the system is designed suchthat the three way mixing port closes against the 'hot supply', resulting in stopping the flow to warmwater outlets.

The hot water supply test simulates the failure of hot water supply to the warm water installation whilsta cold water supply still exists. Under these conditions, the system is designed such that the three waymixing port closes against the 'cold supply', resulting in stopping the flow to warm water outlets.

Perform the ‘cold supply failure test’ and ‘hot supply failure test’ as described in the section“PERFORMANCE CHECKING PROCEDURES” on page 18.

Management of Legionella Bacteria Risk during Commissioning

Local regulations and requirements may require that specific activities associated with the riskmanagement of legionella bacteria be carried out before the warm water system is made available foruse. These activities may include disinfecting warm water system pipework, collecting water samplesand having them analysed for legionella bacteria content and the person(s) responsible for the warmwater valve and associated plumbing infrastructure granting permission for the system to be madeavailable for use.

HAND-OVER TO CUSTOMER

After commissioning, the system is ready to be handed over to the customer. Confirm the items onthe checklist below:

1. Confirm that the warm water system and all associated components been commissioned inaccordance with these instructions.

2. Confirm that measurements taken during commissioning have been appropriately recorded (the“COMMISSIONING LOG” on page 23 of these instructions can be used for recording purposes).

3. Remind the customer that the person or organisation responsible for the warm water valve andassociated plumbing infrastructure in a premises must exercise due diligence to ensure that thedelivery temperature does not exceed the allowable temperature for a particular application andthat the risks associated with legionella bacteria are effectively managed. They may need toconform with specific local regulations and requirements in relation to warm water systems andmay require management and maintenance plans to achieve and maintain conformance.

4. Remind the customer of the periodic performance checking and maintenance requirements inthese instructions and that these must be carried out by competent persons who are permitted bylaw to do so.

5. After commissioning it is recommended that the handles for the following valves be removed andkept in a safe place by the person responsible for the warm water valve and associated plumbinginfrastructure in the premises to prevent unauthorised opening or closing:

• Ultraviolet Disinfection System bypass valve

• Cold supply to the three way mixing port

6. It is recommended that the special key for opening the mixing valve controller box is kept awayfrom the warm water valve in a safe place by the person responsible for the warm water valveand associated plumbing infrastructure to prevent unauthorised opening and adjustment.

7. Hand the Commissioning Log to the customer and retain a copy for yourself for future reference.

8. Hand this manual to the customer and remind them to put it in a safe and accessible place forfuture reference.


CHECKING AND MAINTENANCE


GENERAL INFORMATION

It is a requirement in New South Wales that warm water system installations are registered with thelocal council or other relevant regulatory authority. There may be similar requirements in other States.

The Demand Duo Warm Water Valve contains sophisticated and precision engineered componentsand should provide many years of safe and reliable service provided it is installed, commissioned,operated and maintained in accordance with these instructions.

It is recommended that the performance checking and maintenance procedures in these instructionsare carried out and recorded at least once every 12 months. This frequency is intended as a guideonly and may need to be varied depending on site specific operational conditions and any localregulations and requirements. As an example, in healthcare installations the risks to users aregenerally higher than those in non healthcare installations and this would warrant more frequentperformance checking and maintenance in healthcare installations.

For specific information regarding checking and maintenance of the Ultraviolet Disinfection systemrefer to the manufacturers instructions.

Performance checking and maintenance must be performed by competent personnel. The “MAINTENANCE LOG” on page 24 of these instructions can be used for recording purposes.

PERFORMANCE CHECKING PROCEDURES

Checking Water Temperature - Full Test

This test must be performed during commissioning for every installation. If carrying out this test as partof commissioning ensure you have read and fully understood the section “Setting and checking WarmWater Delivery Temperature” on page 16.

This test is also recommended for routine checking of water temperature as part of the performancechecking and maintenance regime.

This test is carried out at both full and partial flow rates.

Step 1. NOTE: This step is carried out during commissioning only. It is not carried out duringroutine checking and maintenance. Set the delivery temperature of the warm water valve inaccordance with the procedure “Checking Water Temperature - Partial Test” on page 19.

Step 2. Open sufficient warm water outlets within the warm water flow and return loop toachieve the design ‘peak flow rate’ of the warm water installation. This is usually 20-30% ofthe total number of warm water outlets. If in doubt consult the system designer.

Step 3. Check and record the temperature at the outlet nearest to the mixed outlet connection ofthe warm water valve.

Step 4. Close all warm water outlets. Step 5. Open the warm water outlet furthest from the mixed outlet connection of the warm water

valve. DO NOT open any other warm water outlets. Check and record the temperature. Step 6. Adjust delivery temperature in accordance with the section “Checking Water Temperature -

Partial Test” on page 19.Step 7. Repeat steps 2 to 6 as required. Step 8. If the delivery temperature cannot be adjusted to the desired temperature refer to the

section “Fault Finding During Performance Checking” on page 22.

Checking the Limit Thermostat and probe bellows

The Limit Thermostat is shown as item on Figure 3, page 13. The temperature probe for the limitthermostat is located in the ‘mixed outlet. The limit thermostat and temperature probe perform acritical safety function. When activated, it results in the 3 way mixing port being closed against the hotsupply and therefore a ‘safe’ warm outlet temperature. It activates only when the mixed outlettemperature reaches the ‘set point’ of the limit thermostat. This set point is reached only when thedeliver temperature exceeds the normal operating range which occurs only during operator error orsevere failure of critical components in the warm water installation.

The ‘set point’ of the limit thermostat is factory set. It must not be altered duringcommissioning. Ensure that the bellows (copper tube) between the limit thermostat housing andtemperature probe is connected and undamaged.

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IMPORTANT


Checking Water Temperature - Partial Test

This test is not suitable for commissioning purposes. It is carried out at low flow rate only. It is suitablefor use only during routine checking of water temperature when it is impracticable to open all warmwater outlets and achieve full flow through the system. The 'Full Test' described above is always thepreferred method for checking water temperature.

Step 1. Open the warm water outlet nearest to the mixed outlet connection of the warm water valveand check and record the temperature. Close this outlet.

Step 2. Open the warm water outlet furthest from the mixed outlet connection of the warm watervalve. Check and record the temperature. Close this outlet.

Step 3. If the delivery temperature is incorrect, the 'Checking water temperature - full test' must beperformed and the delivery temperature adjusted accordingly.

Step 4. If the delivery temperature cannot be adjusted correctly refer to the section 'PerformanceChecking Fault Finding'.

Delivery Temperature Adjustment

Delivery temperature adjustment must only be carried out after performing the “Checking WaterTemperature - Full Test” on page 18.

The delivery temperature obtainable by the end users must be compatible with the intendedapplication and comply with AS 3500.4 and applicable local regulations and requirements. The warmwater valve controller is factory pre-set to deliver warm water at a temperature of 43°C. It can beadjusted on site to deliver water at a temperature in the range of 35°C to 55°C in accordance with thisprocedure.

Delivery temperature adjustment should only be necessary during commissioning or after majorrepairs or alterations to the warm water installation. It should not be necessary during routine checkingand maintenance as there should not be significant changes whilst the warm water system is in normalservice. The cause(s) of any unacceptable delivery temperature change(s) during normal servicemust be investigated and rectified prior to performing delivery temperature adjustments.Procedure asfollows (Refer to Figure 4):

Step 1. Open the acess door to the three waymixing valve controller box using thespecial key supplied.

Step 2. Press the PGM button for amaximum of one second.

Step 3. Press the UP or DOWN buttonsas required to change the deliverytemperature setpoint.

Step 4. Press the PGM button to accept thenew delivery set point.

Step 5. Press the EXIT button to retun tothe normal display.

Step 6. Re-check delivery temperatures inaccordance with the procedure“Checking Water Temperature - FullTest” on page 18.

Figure 4 - Delivery temperature adjustment

It is recommended that the special keyfor opening the controller box is keptaway from the warm water valve in asafe place by the person responsiblefor the warm water valve andassociated plumbing infrastructure toprevent unauthorised opening andadjustment.

Press to decreasedelivery temperature

Press to increasedelivery temperature

IMPORTANT



Differential Pressure Check

The maximum pressure difference between the hot and cold inlets of the three way mixing port underflow conditions (referred to as the dynamic differential pressure) must not exceed 50 kPa for thesystem to perform as specified (see “SPECIFICATIONS” on page 2). This is checked by using asuitable differential pressure gauge and connecting it across the 'cold supply' and 'hot supply'connections to the three way mixing port (Figure 3 - Items and ) and reading the maximumdifferential pressure at full flow conditions. A suitable differential pressure gauge is Ambit Instruments,Model CZ 300 DGC with display range of – 100 kPa to + 100 kPa. This gauge operates via a magneticcoupling with a convoluted diaphgragm sensor. Gauges by other manufacturers with equivalentspecifications are also suitable).

To carry out the Differential Pressure Check follow the steps below (Refer to Figure 2 page 12 andFigure 3 page 13 for valve and connection locations).

Step 1. Close the mains cold water and hot water to the warm water valve system

Step 2. Open any warm water outlet until the flow of warm water reduces to a minimum or stopscompletely to relieve any residual pressure in the installation. Close this warm water outlet.

Step 3. Close the cold supply to the three way mixing port .

Step 4. Ensure the differential pressure gauge isolating valves and are closed. Connect thedifferential pressure gauge across the connection points

Step 5. Open the cold supply to the three way mixing port .

Step 6. Restore the mains cold water and hot water to the warm water valve system.

Step 7. Simultaneously open the differential pressure gauge isolating valves and .

Step 8. Open all warm water outlets to achieve maximum flow through the warm waterinstallation.

Step 9. Check and record the differential pressure. Step 10. If the differential pressure is outside the limit in the “SPECIFICATIONS” on page 2 refer to

the section “Fault Finding During Performance Checking” on page 22.

Cold Water Supply Failure Test

(Refer to Figure 2 page 12 and Figure 3 page 13 for valve and connection locations)

This test simulates the failure of cold water supply to the warm water installation whilst a hot watersupply still exists. Under these conditions, the system is designed such that the three way mixing portcloses against the 'hot supply', resulting in stopping the flow to warm water outlets.

The simulation is carried out by closing the 'cold supply' to the three way mixing port within theDemand Duo warm water valve system. If the flow to warm water outlets stops the systemoperation is correct.

To carry out the cold water supply failure test follow the steps below:


Step 2. Check and record the temperature at the warm water outlet nearest to the mixed outletconnection of the warm water valve.

Step 3. Close the 'cold supply' to the three way mixing port .

It is recommended that the handles for the cold and hot supply valves to the three waymixing port are removed during normal operation and kept in a safe place by theperson responsible for the warm water valve and associated plumbing infrastructureto prevent unauthorised adjustment. These handles will need to be retrieved andtemporarily fitted for this test.

It is recommended that the handle for the cold supply valve to the three way mixingport is removed and kept in a safe place by the person responsible for the warmwater valve and associated plumbing infrastructure in the premises to preventunauthorised opening or closing. This handle will need to be retrieved andtemporarily fitted for this test.

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Step 4. Record the maximum temperature at the warm water outlet nearest to the mixed outletconnection of the warm water valve and whether the water flow stops.

Step 5. Open the 'cold supply' to the three way mixing port ..

Step 6. Record whether water flow recommences at the outlet nearest to the mixed outletconnection of the warm water valve and record the maximum and stabilisedtemperatures.

Step 7. If the flow to warm water outlets does not stop refer to the section “Fault Finding DuringPerformance Checking” on page 22.

Step 8. Remove the handle of the cold supply valve to the three way mixing port for safekeeping by the person responsible for the warm water valve and associated plumbinginfrastructure in the premises to prevent unauthorised opening or closing.

Hot Water Supply Failure Test

(Refer to Figure 2 page 12 and Figure 3 page 13 for valve and connection locations)

This test simulates the failure of hot water supply to the warm water installation whilst a cold watersupply still exists. Under these conditions, the system is designed such that the three way mixing port

closes against the 'cold supply' , resulting in stopping the flow to warm water outlets .

The simulation is carried out by closing the 'hot supply' to the Warm Water Valve System . If theflow to warm water outlets stops system operation is correct.

To carry out the hot water supply failure test follow the steps below:


Step 2. Check and record the temperature at the warm water outlet nearest to the mixed outletconnection of the Warm Water Valve System .

Step 3. Close the 'hot supply' to the Warm Water Valve System .

Step 4. Record the maximum temperature at the warm water outlet nearest to the mixed outletconnection of the warm water valve and whether the water flow stops.

Step 5. Open the 'hot supply' to the Warm Water Valve System .

Step 6. Record whether water flow recommences at the warm water outlet nearest to the mixedoutlet connection of the warm water valve and record the maximum and stabilisedtemperatures.

Step 7. If the flow to warm water outlets does not stop refer to the section “Fault Finding DuringPerformance Checking” on page 22.

It is recommended that the handle for the hot supply valve to the Warm Water ValveSystem is removed and kept in a safe place by the person responsible for the warmwater valve and associated plumbing infrastructure in the premises to preventunauthorised opening or closing. This handle will need to be retrieved andtemporarily fitted for this test.

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Testing Associated With The Management Of Legionella Bacteria Risk

Carry out periodic testing of the Ultraviolet Disinfection system in accordance with manufacturersinstructions and any local regulations and requirements.

Local regulations and requirements may also require that specific testing activities associated with therisk management of legionella bacteria are carried out on the warm water system. These activitiesmay include the collection of water samples and having them analysed for legionella bacteria contentand keeping appropriate records.

Fault Finding During Performance Checking

The table below applies when performance checking of the warm water valve is being carried out anda fault is apparent.

MAINTENANCE PROCEDURES

Three way mixing port

The three way mixing port and controller require no periodic maintenance. If the mixing port orcontroller are faulty they must be returned to Rinnai.

The port contains sophisticated and precision engineered components and are individually checkedand calibrated during manufacture. Any unauthorised disassembly and reassembly will void thefactory checks and calibration and may result in a dangerous situation if re-used.

System strainers

System strainers will require periodic cleaning to maintain optimum system operation. Figure 3 showsthe likely locations of strainers. The number of strainers and their location may vary from installationto installation.

Maintenance associated with the management of Legionella bacteria risk

Carry out maintenance of the Ultraviolet Disinfection system in accordance with manufacturersinstructions and any local regulations and requirements.

Local regulations and requirements may also require that specific maintenance activities associatedwith the risk management of legionella bacteria are carried out on the warm water system. Theseactivities may include flushing and disinfection of warm water system pipework and keepingappropriate records.

TABLE 3 - FAULT FINDING

FAULT POSSIBLE CAUSES

Delivery temperature not hot enough orgoes hot and cold.

• Warm water valve system power supply switched off. • Warm water valve system thermostat adjusted incorrectly.• No electrical or gas supplies to the hot water system • Incorrectly adjusted hot water system thermostat.• Power supply to circulating pumps switched off.• Circulating pumps not operating correctly (check priming and flow through pumps).• System valves that are meant to be open are shut and vice versa.• Faults in the plumbing pipework (check for cross connections between hot/cold/warm

pipework, non return valves installed the wrong way around etc.) • Blocked strainers.• Design flaws (undersized pumps, undersized hot water system, incorrectly sized or

configured pipework).• Defective three way mixing port or control system.• Defective hot water system .

Dynamic differential pressure exceeds50 kPa.

• Blocked strainers. • System valves that are meant to be open are shut and vice versa. • Faults in plumbing pipework (check for non return valves installed the wrong way

around, incorrect positioning of pressure limiting valves).• Incorrectly designed pipework between warm water valve and (length, size and path).

Flow from warm water outletscontinues during hot water supplyfailure tests.

• Warm water valve system power supply switched off • System valves that are meant to be open are shut and vice versa. • Faults in the plumbing pipework (check for cross connections between hot/cold/warm

pipework, non return valves installed the wrong way around etc.) • Defective three way mixing valve or control system.


COMMISSIONING LOG

Model/serial Number

Date Of Manufacture / / Date Of Commissioning / /

Hot Water System DetailsManufacturer

Model/serial Number

Commissioning Address Details

Name Of Organisation

Address

Phone Number

Contact Person

ITEM RESULT COMMENTS

Water Supply Lines Flushed And Cleaned

Line Strainers Cleared

System Checked For Leaks

Cold Water - Maximum Supply Pressure

Hot Water

Maximum Supply Pressure kPa

Temperature °C

Confirmation Of Warm Water Delivery Temperature

At Furthest Outlet & Max Flow °C

At Nearest Outlet And Min Flow °C

Differential Pressure Check Max Differential kPa

Cold Water Supply Failure Test

Max Temp After Cold Shut °C

Confirm Flow Stops Yes / No

Max Temp After Cold Opened °C

Stablisied Temp After Cold Opened °C

Hot Water Supply Failure Test

Max Temp After Hot Shut °C

Confirm Flow Stops Yes / No

Max Temp After Hot Opened °C

Stabilised Temp After Hot Opened °C

Management Of Legionella Bacteria Risk During Commissioning

Ultraviolet Disinfection System Operational

Removal Of Ultraviolet Disinfection Bypass Valve Handle After Commissioning

Removal Of Cold Supply To Three Way Mixing Port Handle

Special Key For Opening Mixing Port Controller Box Kept In Safe Place

Commissioning Officer Details

Name

Organisation

Phone Number

Signature Date / /


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Rinnai Australia 25Demand Duo Warm Water Valve Owners Guide & Inst - Issue No.2 14/10/09

CONTACTS

Head Office 10-11 Walker Street,Braeside, Victoria 3195P.O. Box 460Tel: (03) 9271 6625Fax: (03) 9271 6622

National Help LinesSales & Service Tel: 1300 555 545* Fax: 1300 555 655*Spare Parts & Technical InfoTel: 1300 366 388* Fax: 1300 300 141**Cost of a local call Higher from mobile or public phones.

Australia Pty. Ltd. ABN 74 005 138 769 Internet: www.rinnai.com.au E-mail: [email protected]

Documents

RINNAI DEMAND DUO WARM WATER VALVE Owners Guide and Installation Instructions